Design of a Meta-Material with Targeted Nonlinear Deformation Response Zachary Satterfield Clemson University, [email protected]
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Clemson University TigerPrints All Theses Theses 12-2015 Design of a Meta-Material with Targeted Nonlinear Deformation Response Zachary Satterfield Clemson University, [email protected] Follow this and additional works at: https://tigerprints.clemson.edu/all_theses Part of the Mechanical Engineering Commons Recommended Citation Satterfield, Zachary, "Design of a Meta-Material with Targeted Nonlinear Deformation Response" (2015). All Theses. 2245. https://tigerprints.clemson.edu/all_theses/2245 This Thesis is brought to you for free and open access by the Theses at TigerPrints. It has been accepted for inclusion in All Theses by an authorized administrator of TigerPrints. For more information, please contact [email protected]. DESIGN OF A META-MATERIAL WITH TARGETED NONLINEAR DEFORMATION RESPONSE A Thesis Presented to the Graduate School of Clemson University In Partial Fulfillment of the Requirements for the Degree Master of Science Mechanical Engineering by Zachary Tyler Satterfield December 2015 Accepted by: Dr. Georges Fadel, Committee Chair Dr. Nicole Coutris, Committee Member Dr. Gang Li, Committee Member ABSTRACT The M1 Abrams tank contains track pads consist of a high density rubber. This rubber fails prematurely due to heat buildup caused by the hysteretic nature of elastomers. It is therefore desired to replace this elastomer by a meta-material that has equivalent nonlinear deformation characteristics without this primary failure mode. A meta-material is an artificial material in the form of a periodic structure that exhibits behavior that differs from its constitutive material. After a thorough literature review, topology optimization was found as the only method used to design meta-materials. Further investigation determined topology optimization as an infeasible method to design meta-materials with the targeted nonlinear deformation characteristics. Therefore, a method was developed in this thesis to logically and systematically design meta-material unit cells using engineering principles to achieve the desired nonlinear response. This method, called the Unit Cell Synthesis Method, requires the designer to have a fundamental understanding of the geometric nonlinearity of an elemental geometry. One or more of these elemental geometries are then systematically combined into a unit cell. A size optimization is performed on promising unit cell concepts to tune the geometry and converge its response towards that of the target. Application of this method was successful in generating a meta- material to meet the response of the rubber pad. The method represented in this thesis is meant to serve as a framework for future designers to develop meta-materials for nonlinear targeted responses. ii DEDICATION To my family and friends. iii ACKNOWLEDGEMENTS This research would not have been possible without the support and collaboration from many individuals. I would like to thank my parents, Nathaniel and June, for their unwavering support. I would not have made it this far without them. Thanks to my sister, Heather, for her unrelenting competition and love that has motivated my success. Thanks to Kara, who has unconditionally supported me throughout my research and the writing of this thesis. I would like to thank all of my committee members for contributing their knowledge and support throughout this research project. I would like to thank Dr. Fadel for providing me with this research opportunity and guiding me through the many stages of the research process. Thanks to Dr. Li for his expertise in finite elements and the enthusiasm he brought to this research. Thanks to Dr. Coutris for her expertise in elasticity and attention to detail throughout this research. I would like to thank Matthew Castanier, Bill Bradford, and the folks at US Army TARDEC for their financial support of this research. I would also like to thank Christopher Cardine of General Dynamics and Joshua Goossens of Tenneco for their collaboration and providing an industrial perspective. I would like to thank my lab-mates in EIB 136 and friends who have contributed to this research. Thanks to Rahul Renu, Vijay Sarthy, and Anthony Garland for their insightful discussions. Thanks to Neehar Kulkarni for his close collaboration and discussion with this research. iv TABLE OF CONTENTS Abstract ..................................................................................................................... ii Dedication .................................................................................................................... iii Acknowledgements ............................................................................................................ iv Table of Tables ................................................................................................................ viii Table of Figures ................................................................................................................. ix Chapter 1. Introduction ..................................................................................................1 1.1. Overview of Abrams Military Track Pad System.................................................1 1.2. Motivation for Replacing Elastomer Track Pad ...................................................3 1.3. Motivation for Designing a Meta-Material ...........................................................6 1.4. Research Questions ...............................................................................................8 1.5. Thesis Outline .......................................................................................................9 Chapter 2. Literature Review.......................................................................................10 2.1. Methods to Design and Optimize Meta-Materials ..............................................10 2.2. Applications in Designing Meta- Materials ........................................................22 2.3. Conclusions .........................................................................................................26 Chapter 3. Designing via Topology Optimization.......................................................28 3.1. Objective .............................................................................................................28 3.2. TO in Optistruct ..................................................................................................28 v TABLE OF CONTENTS (CONTINUED) 3.3. Discussion ...........................................................................................................33 3.4. Conclusions .........................................................................................................40 Chapter 4. Designing via Engineering Principles ........................................................41 4.1. Objective .............................................................................................................41 4.2. Method of Evaluation .........................................................................................41 4.3. Design of the Brick Unit Cell .............................................................................46 4.4. Design of the BrickOval Unit Cell......................................................................52 4.5. Design Considerations ........................................................................................62 4.6. Conclusions .........................................................................................................70 Chapter 5. A Unit Cell Synthesis Method for Meta-Material Design .........................73 5.1. Method Introduction ...........................................................................................73 5.2. Method Description ............................................................................................75 5.3. Discussion ...........................................................................................................83 5.4. Conclusion ..........................................................................................................85 Chapter 6. Conclusions and Future Work ...................................................................87 6.1. Conclusions .........................................................................................................87 6.2. Broader Impact....................................................................................................88 6.3. Future Work ........................................................................................................89 vi TABLE OF CONTENTS (CONTINUED) Chapter 7. References ..................................................................................................91 Appendices ....................................................................................................................96 Appendix A. Python Script for Brick Design ..................................................................97 Appendix B. Python Script for BrickOval Design ........................................................106 vii TABLE OF TABLES Table 4.1 Target % Vertical Deformation Values .................................................45 Table 4.2 Full Factorial Parameters and Values ....................................................51 Table 4.3 Dimensions of Optimized UC................................................................61 Table 4.4 % Difference in Bulk Deformation Comparison Across Load Cases ...64 Table 4.5 Comparison of Bulk Deformation between Scaled Unit